Adhering systems

ABSTRACT

Adhering systems for magnetizable laminates to assist preventing delamination of magnetizable laminates exposed to direct sunlight; and, relating to preventing fouling of cutting blades during cutting of magnetizable laminates.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation-in-part of and is related toand claims priority from prior non-provisional application Ser. No.13/047,669, filed Mar. 14, 2011, entitled “ADHERING SYSTEMS”; whichapplication is related to and claims priority from prior provisionalapplication Ser. No. 61/314,094, filed Mar. 15, 2010, entitled “ADHERINGSYSTEMS”; and, which application is related to and claims priority fromprior provisional application Ser. No. 61/333,224, filed May 10, 2010,entitled “ADHERING SYSTEMS”, the contents of all of which areincorporated herein by this reference and are not admitted to be priorart with respect to the present invention by the mention in thiscross-reference section.

BACKGROUND

This invention relates to adhering systems. More particularly, thisinvention relates to using such adhering systems in connectingmaterials.

In the past, manufacturers and users of flexible magnetizable sheetshave experienced problems relating to delamination when exposed to heat(like in direct sunlight); yet it is often desirable to utilize flexiblemagnetized laminate sheets in areas exposed to direct sunlight.

Additionally, manufacturers and users of flexible magnetizable sheetshave experienced problems relating to adhesive buildup on blades used tocut flexible magnetizable sheets. Often the cutting blades become warmduring the cutting process and the adhesive begins to foul the cuttingblades. Once the blades are fouled, the cutting process must be stoppedand the blades cleaned; or the adhesive residue will begin to hindercutting and transfer to the surface of the flexible magnetic sheets.

OBJECTS AND FEATURES OF THE INVENTION

A primary object and feature of the present invention is to providesystems overcoming the above-mentioned problems.

It is a further object and feature of the present invention to providesuch systems utilizing preferred adhesives and adhering systems.

Another primary object and feature of the present invention is toprovide such systems having resistance to heat-induced delamination.

A further object and feature of the present invention is to provide suchsystems having an adhesive left non-tacky after curing.

It is yet another object and feature of the present invention to providesuch systems which, when undergoing cutting procedures, prevent buildupof adhesive materials on cutting blades.

A further primary object and feature of the present invention is toprovide such a system that is efficient, inexpensive, and handy. Otherobjects and features of the present invention will become apparent withreference to the following descriptions.

SUMMARY OF THE INVENTION

In accordance with a preferred embodiment hereof, this inventionprovides a system, relating to preventing delamination of magnetizablelaminates exposed to direct sunlight and relating to preventing foulingof cutting blades during cutting of magnetizable laminates, such systemcomprising: at least one flexible magnetizable laminate comprising atleast two layers; wherein such at least two layers comprises at leastone magnetizable layer structured and arranged to be capable ofmagnetization; and at least one adhesive structured and arranged toadhere such at least two layers together; wherein such at least oneadhesive is resistant to transfer from such at least one flexiblemagnetizable laminate to the cutting blades during cutting of such atleast one flexible magnetizable laminate; and wherein such at least oneflexible magnetizable laminate is resistant to delamination during usein direct sunlight.

Moreover, it provides such a system wherein such at least one adhesivecomprises at least one hot-melt adhesive. Additionally, it provides sucha system wherein such at least one adhesive comprises at least onereactive hot-melt adhesive. Also, it provides such a system wherein suchat least one adhesive comprises at least one virtually-thermosetablehot-melt adhesive. In addition, it provides such a system wherein suchat least one adhesive comprises at least one humidity-curable adhesivestructured and arranged to cure using humidity. And, it provides such asystem wherein such at least one adhesive comprises primarilypolyurethane. Further, it provides such a system wherein such at leastone adhesive comprises at least about 90% polyurethane. Even further, itprovides such a system wherein such at least one adhesive comprises atleast about 95% polyurethane. Moreover, it provides such a systemwherein such at least one adhesive comprises at least one thermoplastichot-melt adhesive. Additionally, it provides such a system wherein suchat least one adhesive comprises a melting point greater than 150 degreesFahrenheit. Also, it provides such a system wherein such at least oneadhesive comprises primarily ethylene vinyl acetate. In addition, itprovides such a system wherein such at least one adhesive comprisesflexibility at room temperature.

In accordance with another preferred embodiment hereof, this inventionprovides a method, relating to laminating magnetizable laminates havingat least one adhesive preventing delamination of magnetizable laminatesexposed to direct sunlight and preventing fouling of cutting bladesduring cutting of magnetizable laminates, such method comprising thesteps of: obtaining at least two layers of flexible material; whereinsuch at least two layers comprises at least one magnetizable layerstructured and arranged to be capable of magnetization; and laminatingsuch at least two layers of flexible material with at least one adhesiveto form at least one flexible magnetizable laminate; and curing such atleast one adhesive to form a virtual thermoset; wherein such at leastone adhesive is resistant to transfer from such at least one flexiblemagnetizable laminate to the cutting blades during cutting of such atleast one flexible magnetizable laminate; and wherein such at least oneflexible magnetizable laminate is resistant to delamination on exposureto direct sunlight, during use.

In accordance with another preferred embodiment hereof, this inventionprovides a system, relating to preventing delamination of magnetizablelaminates exposed to direct sunlight and relating to preventing foulingof cutting blades during cutting of magnetizable laminates, such systemcomprising: at least one magnetization accepter structured and arrangedto accept magnetization; at least one indicia accepter structured andarranged to accept indicia; and at least one laminator structured andarranged to laminate such at least one magnetization accepter and suchat least one indicia accepter to form at least one flexible magnetizablelaminate; wherein such at least one laminator is resistant to transferfrom such at least one flexible magnetizable laminate to the cuttingblades during cutting of such at least one flexible magnetizablelaminate; and wherein such at least one flexible magnetizable laminateis resistant to delamination during use in direct sunlight. And, itprovides such a system wherein such at least one laminator comprises atleast one hot-melt adhesive. Further, it provides such a system whereinsuch at least one laminator comprises at least one reactive hot-meltadhesive. Even further, it provides such a system wherein such at leastone laminator comprises at least one virtually-thermosetable hot-meltadhesive. Moreover, it provides such a system wherein such at least onelaminator comprises at least one humidity-curable adhesive structuredand arranged to cure using humidity. Additionally, it provides such asystem wherein such at least one laminator comprises primarilypolyurethane. Also, it provides such a system wherein such at least onelaminator comprises at least about 90% polyurethane. In addition, itprovides such a system wherein such at least one laminator comprises atleast about 95% polyurethane. And, it provides such a system whereinsuch at least one laminator comprises at least one thermoplastichot-melt adhesive. Further, it provides such a system wherein such atleast one laminator comprises a melting point greater than 150 degreesFahrenheit (65 degrees Celsius). Even further, it provides such a systemwherein such at least one laminator comprises primarily ethylene vinylacetate. Even further, it provides such a system wherein such at leastone laminator comprises flexibility at room temperature.

In accordance with another preferred embodiment hereof, this inventionprovides a system, relating to preventing delamination of magnetizablelaminates exposed to direct sunlight and relating to preventing foulingof cutting blades during cutting of magnetizable laminates, such systemcomprising: magnetization accepter means for accepting magnetization;indicia accepter means for accepting indicia; and laminator means forlaminating such magnetization accepter means and such indicia acceptermeans to form at least one flexible magnetizable laminate; wherein suchlaminator means is resistant to transfer from such at least one flexiblemagnetizable laminate to the cutting blades during cutting of such atleast one flexible magnetizable laminate; and wherein such at least oneflexible magnetizable laminate is resistant to delamination during usein direct sunlight. In accordance with preferred embodiments hereof,this invention provides for each and every novel feature, element,combination, step and/or method disclosed or suggested by this patentapplication.

According to another preferred embodiment of the present invention, thisinvention provides each and every novel feature, element, combination,step and/or method disclosed or suggested by this patent application.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross-sectional view, of a flexible magnetic sheet,illustrating a preferred embodiment of the present invention.

FIG. 2 shows a diagrammatic view illustrating a preferred manufacturingprocess of the preferred embodiment of FIG. 1.

FIG. 3 shows a flowchart illustrating the preferred manufacturingprocess of FIG. 2.

FIG. 4 shows a diagrammatic view illustrating a preferred coating stageof an alternately preferred manufacturing process of the preferredembodiment of FIG. 1.

FIG. 5 shows a diagrammatic view illustrating a preferred adhering stageof the alternately preferred manufacturing process of the preferredembodiment of FIG. 1.

FIG. 6 shows a flowchart illustrating an alternately preferredmanufacturing process of FIG. 4 and FIG. 5.

DETAILED DESCRIPTION OF THE BEST MODES AND PREFERRED EMBODIMENTS OF THEINVENTION

FIG. 1 shows a cross-sectional view of a flexible magnetic sheetillustrating a preferred embodiment of the present invention. FIG. 1shows adhering system 100. Adhering system 100 preferably comprisesflexible magnetic sheet 101, as shown. Flexible magnetic sheet 101preferably comprises at least one magnetizable layer 110, at least oneadhesive layer 115, and at least one writeable layer 120, as shown.Magnetizable layer 110 preferably comprises magnetizable material.Adhesive layer 115 preferably connects magnetizable layer 110 withwriteable layer 120. Writeable layer 120 is preferably capable ofholding indicia, preferably obtained through printing or alternatelypreferably obtained through writing.

Magnetizable layer 110 preferably comprises at least one magnetizablecomponent (preferably ferrite particles) and preferably at least onebinder. The at least one magnetizable component and the at least onebinder are preferably homogeneously blended and shaped to formmagnetizable layer 110 (at least herein embodying wherein said at leasttwo layers comprises at least one magnetizable layer structured andarranged to be capable of magnetization). Magnetizable layer 110 ispreferably flexible, preferably from flexibility properties of the atleast one binder, and is preferably magnetizable, so as to be useful inmagnetically adhering to a magnetically receptive surface, preferablyfrom ferromagnetic properties of the at least one magnetizablecomponent. Magnetizable layer 110 is preferably smooth so that nosurface treatment is required in adhering magnetizable layer 110 towriteable layer 120. Under appropriate circumstances, those of ordinaryskill in the art will now appreciate that, under appropriatecircumstances, considering such issues as cost, future technologies,etc., other arrangements of layers, such as, for example, a non-magneticlayer, layers utilizing other properties creating magnetic-likeattraction, etc., may suffice.

Writeable layer 120 is preferably capable of being printed on,alternately preferably capable of being written on. Writeable layer 120preferably comprises bi-axially oriented polypropylene film (“BOPP”),alternately preferably paper, alternately preferably vinyl, alternatelypreferably non-top-coated vinyl, alternately preferably polypropylene,alternately preferably synthetic paper, alternately preferably coatedpaper. Such synthetic paper preferably comprises waterproof syntheticpaper. Such synthetic paper preferably comprises a thickness of about 5mil (about 127 micrometers). Such synthetic paper preferably comprisesYUPO® synthetic paper (commercially available from Yupo CorporationAmerica, 800 Yupo Court, Chesapeake, Va. 23320, www.yupousa.com),alternately preferably Polylith® synthetic paper (commercially availablefrom Granwell Products, 185 Fairfield Ave, #2B, West Caldwell, N.J.07006, USA, www.granwell.com), alternately preferably HOP-SYNC)synthetic paper (commercially available from Hop Industries Corporation,1251 Valley Brook Avenue, Lyndhurst, N.J. 07071, www.hopindustries.com).Such YUPO® synthetic paper preferably comprises YUPO® Blue-SyntheticPaper Indigo Printable preferably about 3.8 mil (96 micrometer) thick,alternately preferably YUPO® FEB 130 Synthetic Paper Offset Printablepreferably about 5.1 mil (about 129 micrometer) thick, alternatelypreferably SPG 080 Synthetic Paper Indigo Printable preferably about 3.2mil (about 81 micrometer) thick, alternately preferably SPG 080Synthetic Paper with solvent ink jet printable coating one side,alternately preferably FPU 150 Synthetic Paper UV Printable preferablyabout 5.9 mil (about 150 micrometer) thick, alternately preferablySPG080 Synthetic Paper Indigo Printable preferably about 5 mil (about127 micrometer) thick. Such HOP-SYNC) synthetic paper preferablycomprises HOP-SYNC) Synthetic Paper Matte preferably about 4.1 mil(about 104 micrometer) thick. Such coated paper preferably comprisesUtopia coated paper (commercially available from Sterling Paper Company,1845 Progress Ave, Columbus, Ohio 43207, www.sterling-paper.com),preferably Utopia Two 80# Gloss Text Paper, alternately preferablyUtopia Two 100# Gloss Text Paper, alternately preferably Utopia Two 65#Gloss Cover Paper, alternately preferably Utopia Two 70# Semi-Gloss TextPaper. Alternately preferably, such coated paper preferably comprisesFutura® coated paper (commercially available from NewPage Corporation,8540 Gander Creek Dr, Miamisburg, Ohio 45342, www.newpagecorp.com).Alternately preferably, such coated paper preferably comprises 10 Pt.Carolina C1S (coated one side) Paper (commercially available fromXpedx®, 9797 Sweet Valley Drive, Cleveland, Ohio 44125, www.xpedx.com).Such bi-axially oriented polypropylene film preferably comprises 66LT440BOPP (coated one side) (commercially available from ExxonMobil ChemicalCompany, 13501 Katy Freeway, Houston, Tex. 77079-1398,www.exxonmobilchemical.com). Upon reading the teachings of thisspecification, those of ordinary skill in the art will now appreciatethat, under appropriate circumstances, considering such issues as cost,future technologies, etc., other materials providing additionalfunctionality, such as, for example, cork, fabric, sandpaper, anothermagnetizable layer, paramagnetic materials, etc., may suffice

Magnetizable sheet 101 (at least embodying herein at least one flexiblemagnetizable laminate comprising at least two layers) is preferablyformed into a roll or alternately preferably cut into specific sizesbased on customer desire.

Upon reading the teachings of this specification, those of ordinaryskill in the art will now appreciate that, under appropriatecircumstances, other arrangements of the sheet, such as, for example,sandpaper layer connected to magnetizable layer; cork layer connected tomagnetizable layer; wood layer connected to magnetizable layer;decorative print layer connected to magnetizable layer; wallpaperconnected to magnetizable layer; two magnetizable layers connected toone another with magnetic poles in a “repulsive” orientation; twomagnetizable layers connected to one another with magnetic poles in an“attractive” orientation; two magnetizable layers connected to oneanother with “opposite” indicia on opposing sides (e.g., On/Off;Open/Closed, Stop/Go, etc.), etc., may suffice.

Adhesive layer 115 (at least embodying herein at least one adhesivestructured and arranged to adhere said at least two layers together)preferably comprises adhesive 117 bonding magnetizable layer 110 withwriteable layer 120. Adhesive 117 preferably comprises at least onehot-melt adhesive, preferably at least one reactive hot-melt adhesive,preferably at least one virtually-thermosetable hot-melt adhesive.Adhesive 117 preferably comprises polyurethane, alternately preferablyethylene vinyl acetate (a hot-melt adhesive), alternately preferablymoisture-curing urethane adhesive. Upon reading the teachings of thisspecification, those skilled in the art will now appreciate that, underappropriate circumstances, considering such issues as cost, futuretechnologies, available materials, etc., other adhesives, such as, forexample, other polymers, dissipating chemical reagents, fusingcross-linking materials, etc., may suffice.

Adhesive 117 preferably bonds destructively to magnetizable layer 110and writeable layer 120, meaning that once adhesive 117 is cured, thelayers cannot be removed mechanically (by peeling, delamination, etc.)without mechanical destruction. Further, applying normal heat of about110 degrees Fahrenheit (about 43 degrees Celsius) preferably does notinterfere with the bonding qualities of adhesive 117. Further, adhesivelayer 115 preferably is non-tacky once bonded to magnetizable layer 110and writeable layer 120. Adhesive 117 preferably is smoothly appliedwhich provides for a quality print processing. Flexible magnetic sheet101 preferably has no observable bumps, ridges, or streaks in adhesivelayer 115; so writeable layer 120 is preferably likewise smooth forprinting or writing.

Adhesive 117, when comprising polyurethane, is preferably durable,cross-link reacted, and cannot be reactivated after curing. Thecross-linking is preferably non-reversible as occurs with a thermosetpolymer. Additionally, adhesive 117 is preferably heat resistant toresist delamination in high temperatures, while also preferablyremaining flexible at low temperatures. The Applicant has determinedthrough testing that polyurethane remains flexible in cold temperatures.For example, at freezing (32 degrees Fahrenheit, 0 degrees Celsius), thepreferred polyurethane adhesives remain flexible (do not observablycrack, distort, or bubble). Adhesive 117 preferably is solid, preferablynot solvent based, and preferably comprises no volatile organiccompounds. Adhesive 117 preferably is recyclable.

A preferred polyurethane adhesive for adhesive layer 115 comprisesPURMELT® R-246C made available by Henkel Corporation of Elgin, Ill.

PURMELT® R-246C comprises about 95 percent to about 99 percent of apolyurethane prepolymer and about 1-3 percent of Methylene bisphenylisocyanate (CAS No. 101-68-8). The following physical and chemicalproperties belong to PURMELT® R-246C:

-   -   Physical state: Solid    -   Color: Off-white    -   Odor: None    -   Odor Threshold: 0.4 ppm (4,4′-MDI)    -   Vapor pressure: <0.0001 mmHg@20° C. (68° F.) For MDI    -   pH: Not applicable    -   Boiling point/range: Not available    -   Melting point/range: 120° C. (250° F.)    -   Specific gravity: 1.1    -   Vapor density: Not available    -   Evaporation rate: Not applicable    -   Solubility in water: Insoluble. Reacts slowly with water to        liberate carbon dioxide gas.    -   Partition coefficient (n-octanol/water): Not available    -   VOC content: 0 g/L

An alternately preferred polyurethane adhesive is PURMELT® R-246CLV madeavailable by Henkel Corporation of Elgin, Ill. PURMELT® R-246CLV has aviscosity of about 18,000 centipoise at about 180 degrees Fahrenheit(about 82 degrees Celsius) and a humidity curing mechanism. PURMELT®R-246CLV is a one-component polyurethane reactive hot melt adhesive.PURMELT® R-246CLV cures through moisture to form a tough, strong, andvirtually thermoset polymer. Unlike many thermoset polymers, a virtualthermoset polymer retains flexibility and has a melting point lower thanthe decomposition temperature, though higher that before curing. Thus,Adhesive 117, comprising a virtual thermoset polymer, preferably bondsusing cross-linking, preferably increasing the melting point, butpreferably maintains flexibility and recyclability. Further, anotheralternately preferable adhesive is Supergrip 2000™ H0005-03A by Bostik™companies, a solvent-free, one component, moisture curing urethaneadhesive which, once dispensed will react with ambient moisture to yielda cross-linked virtual thermoset adhesive.

FIG. 2 shows a diagrammatic view illustrating a preferred manufacturingprocess 200 of the preferred embodiment of FIG. 1. FIG. 3 shows aflowchart illustrating preferred manufacturing process 200 of FIG. 2. Toconstruct magnetizable sheet 101, manufacturing process 200 begins withthe step of Obtaining Magnetizable Layer and Writeable Layer 310 (atleast embodying herein obtaining at least two layers of flexiblematerial), in which magnetizable layer 110 and writeable layer 120 areobtained preferably as rolls of material (magnetizable-layer roll 230and writeable-layer roll 210). Upon reading the teachings of thisspecification, those skilled in the art will now appreciate that, underappropriate circumstances, considering such issues as cost, productdemand, future technologies, etc., other layer combinations, such as,for example, sandpaper layer connected to magnetizable layer; cork layerconnected to magnetizable layer; wood layer connected to magnetizablelayer; decorative print layer connected to magnetizable layer; wallpaperconnected to magnetizable layer; two magnetizable layers connected toone another with magnetic poles in a “repulsive” orientation; twomagnetizable layers connected to one another with magnetic poles in an“attractive” orientation; two magnetizable layers connected to oneanother with “opposite” indicia on opposing sides (e.g., On/Off;Open/Closed, Stop/Go, etc.), etc., may suffice.

In step Apply Adhesive 320, preferably, an increased temperature,preferably about 250 degrees Fahrenheit (about 121 degrees Celsius), isapplied to a pre-selected amount of adhesive 117. Thus prepared,adhesive 117 is subsequently applied to a coating machine 220,preferably in a coating bath 222. Preferably, coating machine comprisesa Gravure coater (as shown in FIG. 2), alternately preferably a rollcoater, alternately preferably a slot die coater. Upon reading theteachings of this specification, those skilled in the art will nowappreciate that, under appropriate circumstances, considering suchissues as cost, available materials, future technologies, etc., othercoating devices, such as, for example, Meyer rod coaters, blade-gapcoaters, reverse-roll coaters, air-knife coaters, etc., may suffice.

Engraved roller 226, of coating machine 220, preferably collectsadhesive from coating bath 222 and preferably applies adhesive 117 towriteable layer 120. Preferably, at least one doctor blade 224 wipes offexcess adhesive from engraved roller 226 prior to application towriteable 120. At least one pressure roller 228 applies pressure toassist adhesion of adhesive 117 to writeable layer 120 from engravedroller 226. Coating machine 220 preferably coats adhesive 117 in a thinlayer (adhesive layer 115) so that magnetizable layer 110 and writeablelayer 120 will sandwich adhesive layer 115. Adhesive layer 115preferably comprises a thickness of about 0.6 mil to about 1.5 mil(about 1.5 micrometers to about 4 micrometers). Upon reading theteachings of this specification, those skilled in the art will nowappreciate that, under appropriate circumstances, considering suchissues as cost, available materials, coating methods, etc., otherthicknesses of adhesive may suffice.

Preferably the viscosity of adhesive 117 is kept at a pre-selectedlevel, preferably to apply an even layer. PURMELT® R-246C has aviscosity of about 13,000 centipoise at about 250 degrees Fahrenheit(about 121 degrees Celsius). Under appropriate circumstances, such as toachieve a thinner coat weight, the temperature applied to the adhesivemay be increased to “thin” the coat weight. Preferably, coating machine220 comprises a Gravure coater, as shown in FIG. 2, alternatelypreferably a reverse Gravure coater, so that a consistent coat weightmay be preferably deposited onto the desired layer(s). The Gravurecoating structure (engraved roller 226) comprises engravings having apre-determined depth so as to deposit a controlled coat weight onto adesired layer. Engraved roller 226 preferably comprises at least onequad pattern, preferably a 55 by 55 quad pattern, alternately preferablya 96 by 96 quad pattern. Alternately, engraved roller 226 preferablycomprises at least one tri-helical pattern. Alternately, engraved roller226 preferably comprises at least one hex channel pattern, preferably a45 degree hex channel pattern. For most printing applications, adhesivelayer 115 has a preferred thickness of about 0.6 mil to about 1.5 mil(about 1.5 micrometers to about 4 micrometers).

After applying adhesive 117 forming adhesive layer 115, magnetizablelayer 110 is preferably joined to writeable layer 120 with adhesivelayer 115 between to form an adhesive bond, in step Join Layers 330.Adhesive layer 115 preferably is still viscous to promote completebonding, during step Join Layers 330. The resulting bound and layeredmaterial (magnetizable sheet 101) preferably forms as all three layers(magnetizable layer 110, adhesive layer 115 and writeable layer 120) arepressed together through pressure rollers 210. Magnetizable sheet 101preferably is rolled into magnetizable sheet roll 240 ready for finalcuring. The steps of Apply Adhesive 320 and Join Layers 330 at leastembody herein laminating such at least two layers of flexible materialwith at least one adhesive to form at least one flexible magnetizablelaminate.

After joining the layers, magnetizable sheet 101 is preferably cured, instep Cure Adhesive 340 (at least embodying herein curing such at leastone adhesive to form a virtual thermoset). Curing of adhesive preferablyuses humidity. Curing time is preferably dependent on humidity.Preferably, a cure time of 24 hours is preferred in most ambienthumidity conditions (about 28 percent to about 70 percent relativehumidity). Increasing the humidity level preferably decreases the timeneeded to cure the adhesive depending on the coat weight applied to thelayers. Preferably, additional humidity may be preferably introduced byrunning the curing product though a humidified chamber, alternatelypreferably by misting the curing product, or alternately preferablycuring the product in a humidity controlled room. Upon reading theteachings of this specification, those skilled in the art will nowappreciate that, under appropriate circumstances, considering suchissues as available materials, future technologies, costs, etc., othercuring methods, such as, for example, electromagnetic radiation,temperature flux, vacuum, atmospheric adjustments, etc., may suffice.

As PURMELT® R-246C cures, it forms a virtually thermoset polymer.Applicant's testing has shown that the PURMELT® R-246C does not lose itsthermoset polymer qualities at about 110 degrees Fahrenheit, yet remainsflexible.

Applicant's subjected a sample of magnetizable sheet 101 with PURMELT®R-246C and Exxon Mobile Indigo Printable BOPP 970 LT-447 to a “peeltest”, more specifically a 90-degree peel at 12 inches/minute test(about 38 millimeter/minute). The peel test was performed with aCHEMINSTRUMENTS Adhesion Release Tester Model No. AR-1500. The adhesivecoat weight was 0.001 inches. An inability to peel the magnetizablesheet from the Exxon Mobile Indigo Printable BOPP 970 LT-447 wasobserved.

Further, Applicant subjected a sample of magnetizable sheet with AcucoteP2000 pressure sensitive adhesive made available by Acucote Inc. ofGraham, N.C. and Exxon Mobile Indigo printable BOPP (70 LT-447) to thesame above peel test. Adhesive failure (i.e., the adhesive was removedfrom the substrate cleanly) and adhesive transfer (i.e., the adhesivetransferred from the face stock to the substrate) were both observed.

In testing, Applicant has documented the lack of “build up” of adhesive117 on a guillotine cutter blade. A blade test procedure was performedby cutting sheets having a magnetizable layer, a layer of PURMELT®R-246C, and a laminate layer into sheets sized about 12 inches by about18 inches. One hundred sheets were heated to about 110 degreesFahrenheit. The 100 heated sheets were cut 110 times with a guillotinepaper cutter (such as manufactured by POLAR). Photographs of the cuttingblades were taken every 20 cuts. The photographs show no observableadhesive residue on the blade after making 110 cuts. On the other hand,Applicant has observed that a pressure sensitive adhesive utilized inplace of PURMELT® R-246C subjected to the above test will typicallyobservably gather on the knife blade and be transferred to the materialbeing cut after 20 cuts. This property of magnetizable sheets 101 isimportant in that die cut blades become warm during use and pressuresensitive adhesives “gum” up or foul the blades. This arrangement atleast herein embodies wherein said at least one adhesive is resistant totransfer from said at least one flexible magnetizable laminate to thecutting blades during cutting of said at least one flexible magnetizablelaminate; and this arrangement at least herein embodies wherein said atleast one laminator is resistant to transfer from said at least oneflexible magnetizable laminate to the cutting blades during cutting ofsaid at least one flexible magnetizable laminate; and this arrangementat least herein embodies wherein said laminator means is resistant totransfer from said at least one flexible magnetizable laminate to thecutting blades during cutting of said at least one flexible magnetizablelaminate.

In summary, Applicant prefers utilization of adhesive 117, preferablycomprising at least one hot-melt adhesive, preferably at least onereactive hot-melt adhesive, preferably at least onevirtually-thermosetable hot-melt adhesive, preferably primarilypolyurethane, preferably at least about 90% polyurethane, preferably atleast about 95% polyurethane, preferably PURMELT® R-246C. Applicantfurther prefers adhesive 117 comprising polyurethane curable byhumidity, preferably raising the overall melting point while preferablyremaining flexible at room temperature. In addition, Applicant prefersadhesive 117 that, after being cured, will not delaminate while exposedto direct sunlight or high temperature environments (above about 100degrees Fahrenheit or above about 38 degrees Celsius), during use (thisarrangement at least herein embodying wherein said at least one flexiblemagnetizable laminate is resistant to delamination during use in directsunlight). Further Applicant prefers adhesive 117 that, after beingcured, is not tacky when exposed to normal cutting-machine operationaltemperatures (about 110 degrees Fahrenheit or about 43 degrees Celsius),so as to transfer essentially no residue to cutting blades.

Upon further testing, Applicant more preferably utilizes reverse Gravurecoating having a 96 by 96 quad pattern. Applicant found that bonds wereconsiderably better with this pattern and technique. All testedsubstrates showed complete destructive bonding within 72 hours ofapplication.

FIG. 4 shows a diagrammatic view illustrating a preferred coating stage205 of an alternately preferred manufacturing process 201 of thepreferred embodiment of FIG. 1. FIG. 5 shows a diagrammatic viewillustrating a preferred adhering stage 207 of alternately preferredmanufacturing process 201 of the preferred embodiment of FIG. 1. FIG. 6shows a flowchart illustrating alternately preferred manufacturingprocess 201 of FIG. 4 and FIG. 5. An alternately preferred adhesive 117,comprising ethylene vinyl acetate, preferably comprises HOT MELT NO.C53-133 PLW by Cattie Adhesive Solutions of Quakertown, Pa. HOT MELT NO.C53-133 PLW is a synthetic resin, having a white amber color, viscosityof about 1400-1900 centipoise at about 225 degrees Fahrenheit (about 107degrees Celsius), viscosity of about 1100-1600 centipoise at about 250degrees Fahrenheit (about 121 degrees Celsius), viscosity of about400-600 at 300 degrees Fahrenheit (about 150 degrees Celsius), asoftening point (ring and ball) at 160 degrees Fahrenheit (about 71degrees Celsius), a speed of set of medium/fast, and no noticeableadverse effects after 100 hours at 350 degrees Fahrenheit (about 177degrees Celsius). HOT MELT NO. C53-133 PLW is a thermoplastic.

In applying the HOT MELT NO. C53-133 PLW, manufacturing process 201 waspreferred. Manufacturing process 201 preferably comprises step ObtainingMagnetizable Layer and Writeable Layer 310 like manufacturing process200. Manufacturing process 201 further comprises 2 stages, first,coating stage 205, as shown in FIG. 4, and second, adhering stage 207,as shown in FIG. 5.

In coating stage 205, first, adhesive 117, comprising HOT MELT NO.C53-133 PLW, is applied to writeable layer 120, in step Apply Adhesive320 (detailed above in manufacturing process 200). After applyingadhesive 117 to form adhesive layer 115, adhesive layer 115 is allowedto cool, in step Cool Adhesive 325. Upon cooling, and thus inactivationof adhesive properties of adhesive layer 115, the combined material ofwriteable layer 120 and adhesive layer 115 is then wound onto a core toform coated-material roll 250, as shown in FIG. 4, completing coatingstage 205 of manufacturing process 201.

A typical application temperature of HOT MELT NO. C53-133 PLW rangesbetween about 220 to about 300 degrees Fahrenheit (about 104 degreesCelsius to about 150 degrees Celsius). Preferably, HOT MELT NO. C53-133PLW is applied at about 250 degrees Fahrenheit preferably using a slotdie coating technique, alternately preferably using a Gravure coater, asshown in FIG. 4. Upon reading the teachings of this specification, thoseskilled in the art will now appreciate that, under appropriatecircumstances, considering such issues as cost, available materials,future technologies, etc., other coating devices, such as, for example,Meyer rod coaters, blade-gap coaters, reverse-roll coaters, air-knifecoaters, etc., may suffice.

In adhering stage 207, coated material from coated-material roll 250 andmagnetizable layer 110 are then subsequently run together over at leastone heated roller 215 (to reactivate adhesive 117) to bond the writeablelayer 120 (at least embodying herein at least one indicia accepterstructured and arranged to accept indicia; and at least embodying hereinindicia accepter means for accepting indicia) to magnetizable layer 110(at least embodying herein at least one magnetization accepterstructured and arranged to accept magnetization; and at least embodyingherein magnetization accepter means for accepting magnetization) withadhesive layer 115 sandwiched between, in step Join Layers Adding Heat335. After being thus joined, magnetizable sheet 101 forms. Magnetizablesheet 101 is preferably allowed to cool in step Cool Adhesive 345. Inmanufacturing process 201, magnetizable sheet 101 is not cured furtherand adhesive 117 (at least embodying herein at least one laminatorstructured and arranged to laminate said at least one magnetizationaccepter and said at least one indicia accepter to form at least oneflexible magnetizable laminate; and at least embodying herein laminatormeans for laminating said magnetization accepter means and said indiciaaccepter means to form at least one flexible magnetizable laminate)preferably stays as a thermoplastic, however adhesive 117, comprisingHOT MELT NO. C53-133 PLW, has a high melting point so preferablyprevents delamination except in temperatures unlikely to occur in normaluse (above 220 degrees Fahrenheit or about 104 degrees Celsius). Aftercooling, magnetizable sheet 101 is preferably rolled into magnetizablesheet roll 240.

In summary, Applicant alternately prefers utilization of adhesive 117,preferably comprising at least one hot-melt adhesive, preferably atleast one thermoplastic hot-melt adhesive, preferably primarily ethylenevinyl acetate, preferably HOT MELT NO. C53-133 PLW. In this alternatepreference, Applicant further prefers adhesive 117 comprising ethylenevinyl acetate with a melting point of greater than 150 degrees, whilepreferably remaining flexible at room temperature. In addition, in thisalternate preference, Applicant prefers adhesive 117 that will notdelaminate in direct sunlight or high temperature environments (aboveabout 100 degrees Fahrenheit or about 38 degrees Celsius), during use.Further, in this alternate preference, Applicant prefers adhesive 117that is not tacky when exposed to normal cutting-machine operationaltemperatures (about 110 degrees Fahrenheit or about 43 degrees Celsius),so as to transfer essentially no residue to cutting blades.

Although applicant has described applicant's preferred embodiments ofthis invention using metric standardized units, such measurements havebeen provided only for the convenience of the reader and should not beread as controlling or limiting. Instead, the reader should interpretany measurements provided in English standardized units as controlling.Any measurements provided in metric standardized units were merelyderived through strict mechanical coding, with all converted valuesrounded to reasonable significant figures.

Although applicant has described applicant's preferred embodiments ofthis invention, it will be understood that the broadest scope of thisinvention includes modifications such as diverse shapes, sizes, andmaterials. Such scope is limited only by the below claims as read inconnection with the above specification. Further, many other advantagesof applicant's invention will be apparent to those skilled in the artfrom the above descriptions and the below claims.

What is claimed is:
 1. A flexible magnetizable laminate configured toresist delamination when exposed to direct sunlight and fouling ofcutting blades, said laminate prepared by a method comprising: providingat least one magnetizable layer; providing at least one writable layercapable of holding indicia thereon; providing at least one adhesive;printing said at least one adhesive in a particular pattern onto atleast one of said at least one magnetizable layer and said at least onewritable layer at a temperature of at least 250° F. prior to joiningthese layers together; applying pressure onto said flexible magnetizablelaminate after joining said at least one magnetizable layer and said atleast one writable layer together; curing said at least one adhesive toform an adhesive layer containing a virtual thermoset adhesive polymerthat is a solid, heat resistant, durable, and non-reversiblycross-linked polymer, wherein said at least one adhesive comprises atleast about 90% polyurethane prepolymer before curing, and upon curingbecomes resistant to transfer from said at least one flexiblemagnetizable laminate to the cutting blades during cutting and resistantto delamination during use in direct sunlight, and wherein the adhesivelayer has a thickness of 0.6 mil to 1.5 mil.
 2. The system according toclaim 1 wherein said at least one adhesive comprises a melting pointgreater than 150 degrees Fahrenheit.
 3. The system according to claim 1wherein said at least one adhesive is flexible at room temperature. 4.The system according to claim 1 wherein at least one layer of said atleast one magnetizable layer and at least one writable layer comprisessynthetic paper.
 5. The system according to claim 1 wherein said atleast one writeable layer comprises synthetic paper.
 6. The systemaccording to claim 1 wherein said at least one writeable layer compriseswaterproof synthetic paper.
 7. The system according to claim 1, whereinsaid at least one magnetizable layer and at least one writable layer arejoined together under pressure through pressure rollers.
 8. The systemaccording to claim 1, wherein the printed pattern is at least oneselected from the group consisting of a quad pattern, tri-helicalpattern, and a hex channel pattern.
 9. The system according to claim 1,wherein the printed pattern is one selected from the group consisting ofa 55 by 55 quad pattern, and a 96 by 96 quad pattern.
 10. The systemaccording to claim 1, wherein the printed adhesive is a printed adhesivelayer having a thickness of 0.6 mil to 1.5 mil.
 11. The system accordingto claim 1, wherein after curing, the adhesive bonds destructively tosaid magnetizable layer and said writeable layer.
 12. A method offorming a flexible magnetizable laminate in a manner to resistdelamination when exposed to direct sunlight and prevent fouling ofcutting blades, said method comprising the steps of: supplying at leasttwo layers of flexible material, said at least two layers having atleast one magnetizable layer; heating at least one adhesive to at leastabout 250° F.; printing the heated at least one adhesive in a particularpattern onto at least one of said at least two layers; joining said atleast two layers of flexible material together with said at least oneadhesive to form at least one flexible magnetizable laminate; pressingsaid at least two layers together through pressure rollers; and curingsaid at least one adhesive to form an adhesive layer containing avirtual thermoset polymer that is a solid, heat resistant, durable, andnon-reversibly cross-linked adhesive polymer; wherein and upon curingbecomes resistant to transfer from said at least one flexiblemagnetizable laminate to the cutting blades during cutting and resistantto delamination during use in direct sunlight, and wherein the adhesivelayer has a thickness of 0.6 mil to 1.5 mil.
 13. The method according toclaim 12 wherein said at least one writeable layer comprises syntheticpaper.
 14. The method according to claim 12, wherein said at least onewriteable layer comprises waterproof synthetic paper.
 15. The methodaccording to claim 12 wherein said at least one adhesive comprises amelting point greater than 150 degrees Fahrenheit.
 16. The methodaccording to claim 12 wherein said at least one adhesive is flexible atroom temperature.
 17. The method according to claim 12, wherein theprinted pattern is at least one selected from the group consisting of aquad pattern, tri-helical pattern, and a hex channel pattern.
 18. Themethod according to claim 12, wherein the printed pattern is oneselected from the group consisting of a 55 by 55 quad pattern, and a 96by 96 quad pattern.
 19. The method according to claim 12, wherein theprinted adhesive is a printed adhesive layer having a thickness of 0.6mil to 1.5 mil.
 20. The method according to claim 12, wherein aftercuring, the adhesive bonds destructively to said magnetizable layer andsaid writeable layer.